STUDY, DESIGN AND FABRICATION OF SOLAR BASED

BIOMASS POWER PLANT

Group Members:

ABDUL MOEED ZAFAR (110523)

MUHAMMAD MUDDASSIR (110544)

ALI SAJJAD WASEER (110571)

BE MECHANICAL (2011 2015)

Project Supervisor

Dr. Mehr Nigar

DEPARTMENT OF MECHANICAL AND AEROSPACE ENGINEERING

INSTITUTE OF AVIONICS AND AERONAUTICS

AIR UNIVERSITY, ISLAMABAD

1
STUDY, DESIGN AND FABRICATION OF SOLAR BASED
BIOMASS POWER PLANT

FINAL YEAR PROJECT REPORT

(2011 2015)

DEPARTMENT OF MECHANICAL AND AEROSPACEENGINEERING

2
STUDY, DESIGN AND FABRICATION OF SOLAR BASED
BIOMASS POWER PLANT

Submitted By:

ABDUL MOEED ZAFAR (110523)

MUHAMMAD MUDDASSIR (110544)

ALI SAJJAD WASEER (110571)

Project Supervisor
____________________________

Dr. Mehr Nigar

Head of Department
____________________________

Dr. Basharat Ullah Malik

Chair Department HEC Approved PhD Supervisor

3
 ACKNOWLEDGEMENTS

First and foremost, we would like to thank Almighty Allah in gratitude enabling us to
complete this project. We were in the dark and by the grace of almighty Allah our destination
appears to be in sight.

Language of feelings and sentiments is dumb and cannot be expressed in words; it is a

tragedy. Feelings are to be felt only and not to be converted into words. No one is so
intellectual as to describe feelings or sentiments. Being slaves of traditions, try to express our
feelings and gratitude in words we have for the benefactors.

We pay best of our compliments to our Project Advisor, Dr. Mehr Nigar, who provided
precious technical guidance to us. We are grateful to her because she sacrificed his valued
time and provided all possible facilities and helped us.

We are grateful to Mr. Muhammad Awais from Department of Biochemistry PhD scholar at
Arid Agriculture University for providing us valuable information about our project. We
would like to express our sincere thanks to Sir. Inam-ul-Haq Raja and Dr. Irshad from
Mechanical and Mechatronics departments respectively at Air University. I also thank Mr.
Shariq Khan from UET Taxila for his sincere and valuable guidance in designing of Data
Acquisition system.

Last but not the least; from the depths of our hearts, we express our gratitude and respect to
our loving parents whose blessings, affectionate love, continuous efforts, magnificent
devotions and sacrifices led us to success throughout our academic career.

4
 ABSTRACT
To overcome the energy crises in the world by generation of energy (Bio Gas) using waste
materials like animal dung, fruits, vegetable wastes and other organic wastes. The gas
produced can be used as domestic as well as commercial purposes.

Biogas typically refers to a gas produced by breakdown of organic matter in the absence of
oxygen using fermentation process. Organic wastes such as dead plants and animal wastes,
animal feces, and kitchen wastes can be converted into a gaseous fuel called biogas. Biogas
originates from biogenic material and is a type of bio fuel. The biogas produced can be used
for many purposes such as electricity generation, as fuel in automobiles etc.

When methane is produced by the fermentation of animal dung the gaseous products are
usually referred as biogas and the installations are called biogas plant. Biogas is a flammable
mixture of 65% methane, 35% CO2, 5% water and some other trace gases.

We are using water tube boiler to produce steam which then we use to run turbine and our
generator capacity is of 9 volts which at the end use to provide power to light emitting diodes.

The efficiency of a Bio-gas reactor in winter season (normal temperature) is less than 30%
but as the temperature approaches to 30-40oC, efficiency increases to 60%. Therefore our
focus is to attain a temperature of 35oC and above using the solar energy.

5
TABLE OF CONTENTS

CHAPTER No 1: INTRODUCTION
1.1 Introduction 12
1.2 Biogas 12
1.2.1 Domestic (communal) organic waste 12
1.2.2 Green and plant wastes 12
1.2.3 Communal sewage sludge 12
1.2.4 Liquid or solid manure 13
1.2.5 Energy crops 13
1.2.6 Industrial food waste 13
1.3 Maximal potential of gas production per ton of substrate 13
1.4 Cycle of biogas 14
1.5 Composition of biogas 14
1.6 Fermentation process 15
1.6.1 Types of methanogenic bacteria 15
1.7 pH value 15
1.8 Products of fermentation process 15
1.9 Biogas plant 15
1.10 Development across the world 16
1.10.1 Subcontinent 16
1.10.2 United States 16
1.10.3 Germany 17
1.11 Applications of biogas 17
CHAPTER No 2: SET UP FOR POWER PLANT
2.1 Anaerobic digestion 18
2.1.1.1 Hydrolysis 18
2.1.1.2 Acidogenesis 18
2.1.1.3 Acetogenesis 19
2.1.1.4 Methanogenesis 19
2.1.2 Chemical equations of the overall process 19
2.1.3 Process stages 20
2.1.4 Flow Diagram of the processes 21
2.1.5 Temperature 21

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2.2 Polyvinyl chloride
2.2.1 Chemical properties 22
2.2.1.1 Introduction 22
2.2.1.2 How to produce 22
2.2.1.3 Micro structure 22
2.2.2 Physical Properties 23
2.2.3 Mechanical properties 24
2.2.4 Thermal and fire properties 24
2.2.5 Electrical properties 24
2.2.6 Applications 24
2.2.7 Sustainability 25
2.3 Digester 26
2.3 Size of biogas unit 26
2.3.2 Types of Digester 26
2.3.2.1 Fixed Dome Digesters 26
2.3.2.1.1 Parts of fixed dome digesters 26
2.3.2.1.2 Construction of fixed dome digesters 27
2.3.2.1.3 Operation 27
2.3.2.2 Floating drum digester 28
2.3.2.2.1 Parts of floating drum digester 28
2.3.2.2.2 Construction 28
2.3.2.3 Plug Flow Digester 29
2.3.2.3.1 Main advantages 29
2.3.2.4 Batch digesters 30
2.3.2.5 Continuous digesters 30
2.4 Gasholder 31
2.4.1 Selection of a gasholder 31
2.4.2 Types of Gasholder 21
2.4.2.1 The Klonne Grease Sealed Holder 32
2.4.2.2 Ultra store Membrane Gas holder 32
2.4.2.3 Cable guided gasholders 32
2.4.2.4 Floating Roof Holders 33
2.4.2.5 Spiral guided gasholders 34

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CHAPTER No 3: DESIGN AND CALCULATION
3.1 Design and Calculation of biomass power plant 35
3.1.1 Planning a biogas plant 35
3.1.2 Select a Design 35
3.1.3 Physical conditions 36
3.1.4 Skills and labor 36
3.1.5 Design of Biogas Reactor 36
3.1.6 Selecting a location 36
3.2 Calculation for design 37
3.2.1 Sizing a biogas plant 37
3.2.2 Equations to be used 37
3.2.3 Dimensions of gas holder 38
3.2.4 Dimensions of digester 38
3.2.5 Substrate input quantity 39
3.2.6 Calculating the daily gas production G 39
CHAPTER No 4: ECONOMIC ANALYSIS
4.1 Cost based calculation 40
4.1.1 Cost of mixer 40
4.1.2 Cost of water tank 40
4.1.3 Cost of PVC 40
4.1.4 Cost of filter 40
4.1.5 Power station 40
CHAPTER No 5: FABRICATION
5.1 COMPONENTS 42
5.1.1 Biogas digester 42
5.1.2 Gas holder 44
5.1.3 PVC piping 45
5.1.4 Gas pipe 45
5.1.5 Filters 45
5.1.6 Boiler 45
5.1.6.1 Burner 46
5.1.6.1.1 Flame 46
5.1.7 Steam turbine 46

8
 5.1.8 Fly Wheel 48
5.1.9 Generator 49
5.1.10 Light Emitting Diode 49
5.1.11 Power Bank 49
5.2 Stand 50
5.2.1 Mixer Stand 50
5.2.2 Filter Stand 50
5.2.3 Power Generation setup stand 50
5.2.3.1 Turbine frame 51
5.2.3.2 Boiler stand 51
5.2.3.3 Reservoir Stand 52
5.3 Arduino 52
5.4 Fabricated Model of Biomass power plant 55

CONCLUSION 56
BIBLIOGRAPHY 57
REFERCENCES 58

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List of Figures
Fig. 1.1 Cycle of biogas 14
Fig 1.2 Biogas plant 16
Fig. 2.1 Plug Flow Digester 20
Fig. 2.2 Process stages 20
Fig 2.3 Flow Diagram of the processes 21
Fig 2.4 Handles of victorinox 25
Fig 2.5 Fixed Dome Digesters 27
Fig 2.6 Floating drum digester 28
Fig 2.7 Plug flow digester 29
Fig 2.8 Batch digesters 30
Fig.2.9 the Klonne Grease Sealed Holder 32
Fig.2.10 Ultra store Membrane Gas holder 32
Fig.2.11 Cable guided gasholders 33
Fig.2.12 Floating Roof Holders 33
Fig. 2.13 Spiral Guided Gas Holder 34
Fig. 5.1 Biogas Digester 42
Fig. 5.2 Topless Water tank 42
Fig.5.3 Sliders 43
Fig.5.4 Silicon Sealing 43
Fig. 5.5 Final Digester Design 43
Fig. 5.6 Gas holder 44
Fig. 5.7 PVC 45
Fig. 5.8 Filters 45
Fig. 5.9 Cutting Base of Can with Cutter 46
Fig. 5.10 Bottomless Can 46
Fig. 5.11 Copper tube 46
Fig. 5.12 Super Heat copper tube 46
Fig. 5.13 Copper Tube in Boiler 46
Fig. 5.14 Burner of Boiler 46
Fig. 5.15 Flame Dynamics 47
Fig. 5.16 Aluminum Disc 47
Fig. 5.17 Blades of Turbine 48

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Fig. 5.18 Turbine with stand 48
Fig. 5.19 Fly Wheel 48
Fig. 5.20 Generator 49
Fig. 5.21 LED 49
Fig. 5.22 Power Bank 49
Fig. 5.23 Mixer Stand 50
Fig. 5.24 Filter Stand 50
Fig. 5.25 Power Generation Stand 51
Fig. 5.25.1 Turbine frame 51
Fig. 5.25.2 Boiler Stand 51
Fig. 5.26 Connecting Wires 54
Fig. 5.27 LCD 54
Fig. 5.28 Bread Board 54
Fig. 5.29 Ardino UNO 54
Fig. 5.30 LCD display 55
Fig. 5.31 LM35 Temperature sensor 55
Fig. 5.32 Data Acquisition Circuit 55
Fig. 5.33 Burning code 55
Fig. 5.34 Pressure Gauge 55
Fig. 5.35 Fabricated Model of Biomass power plant 56

List of Tables/Graphs
Table 1.1 Composition of biogas 14
Table 2.2 Physical properties of PVC 23
Table 2.3 Volume of Gas required according to activity 32

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 CHAPTER1
INTRODUCTION

1.1 Introduction:

Biogas is a gas consisting mainly of 65% methane (CH4) and about 35% of carbon dioxide
(CO2). It is a product which is formed by the natural decomposition of any organic substance
of animal or plant origin due to activity of the anaerobic (a non-oxygen environment)
bacteria.[1]

1.2 Biogas:
Organic waste such as dead plants, animal dung and kitchen waste can be converted into
biogas. The major sources of methane are the animal wastes, dead plants, and any other
organic material which is left untreated. Different substrates, which are used in the formation
of biogas are:

1.2.1 Domestic (communal) organic waste:

Domestic organic waste includes separate collected fruit and vegetable wastes, flower soil,
flowers, eggshells, coffee and tea filters and other organic leftovers. The percentage of dry
matter varies between 10 and 30 %.

1.2.2Green and plant wastes:

Lopping and leftovers from cutting gardens or parks which do not contain woody matter

[1] Studies on Biogas Generation from Agricultural Waste; Analysisof the Effects of Alkaline on Gas Generation by I.R.
Ilaboya, 2F.F. Asekhame, 3M.O. Ezugwu, 4A.A. Erameh and 5F.E. Omofuma

1.2.3 Communal sewage sludge:

This sewage sludge contains nitrate, phosphor and heavy metals.

12
1.2.4 Liquid or solid manure:

Cow manure, chicken manure, pig manure

1.2.5 Energy crops:

Corn,Sudan grass, millet, white sweet-clover, green cuttings, maize, grass and whole-
plant silage.

1.2.6 Industrial food waste:

These include substrates from meat production, like slaughterhouse wastes.

1.3 Maximal potential of gas production per ton of substrate: [2]

Cow manure: 25 m2/t

Pig manure: 36 m2/t
Whey: 55 m2/t
Spent grains, duff: 75 m2/t
Lopping: 110 m2/t
Domestic organic waste: 120 m2/t
Industrial food waste: 220 m2/t
Flotation slurry: 400 m2/t
Waste food grease and oils: 600 m2/t

[2] PermaCultureScience.org

13
1.4 Cycle of biogas:

Fig. 1.1 cycle of biogas[2]

1.5 Composition of biogas:

The composition of biogas depends upon origin of the anaerobic digestion process. Landfill
gas has concentration of methane around 50%. Advanced waste treatment technologies can
form biogas with 5575% methane.

In some cases, biogas may contain siloxanes. These are formed due to the anaerobic
decomposition of materials mostly found in soaps and detergents. As the biogas containing
siloxanes is burnt, silicon is released which can combine with free oxygen or any other
elements in the combustion gas.

Compound Molecular formula %

Methane CH4 50-75

Carbon dioxide CO2 25-50

Nitrogen N2 0-10

Hydrogen H2 0-1

Hydrogen Sulphide H2S 0-3

Oxygen O2 0-0

Table 1.1 composition of biogas[3]

14
1.6 Fermentation process:

The bacteria involved in the fermentation process are methanogenic bacteria.

1.6.1 Types of Methanogenic bacteria:

Psychrophilic
Mesophilic
Thermophilic

This subdivision is based upon their optimum temperature range. The optimum temperature
for mesophilic bacteria lies in the range 38C 40C, while the thermophilic group prefers
50C 60C.

1.7 pH value:

The pH value of the fermentation substrate is between weakly acidic (pH 6) and weakly
alkaline (pH 8).

1.8 Products of fermentation process:

The main product formed as a result fermentation process is the biogas, an energy source for
the generation of renewable energy. The major components of biogas i.e methane and carbon
dioxide act as greenhouse gases that can harm the atmosphere if released unburned into the
environment.

1.9 Biogas plant:

Organic materials such as animal wastes, remains of food processing, plants remains,
slaughterhouse leftovers and other organic materials are grounded and fed into large
containers known as digesters. These substrates are heated in the digester to an optimal
temperature so as to produce biogas, which bubbles to the top and is collected in a biogas
container/gasholder. This biogas can be used for many purposes depending on how we want
to use.

15
 Fig 1.2 biogas plant[3]

1.10 Development across the world.

1.10.1 Subcontinent:

In countries like India, Nepal, Pakistan and Bangladesh biogas produced from the
anaerobic digestion of manure in small-scale digestion facilities is called gobar gas.
The digester in this case is a simple airtight circular container made of concrete and
having piping system. The manure is fed to the container (directly from the cattle
shed). The container is then filled with required quantity of water. A gas pipe is
connected directly to the kitchen stove through control valves. The combustion of
this biogas produces little smoke. Because of its simplicity and use of cheap raw
materials, it is widely used in villages.[3]

1.10.2 United States:

In Texas, biogas is used to power a power plant. By using biogas, the power plant has
saved one thousand barrels of oil a day.
According to a study conducted in 2008, by Science and Childrenmagazine, biogas
would be sufficient to produce 100 billion kilowatts of electricity, enough to power
millions of homes across America.
Biogas can reduce 99 million metric tons (about 4 %) of greenhouse gas emissions
produced by America.[3]

16
1.10.3 Germany:

Germany is the biggest biogas producer in Europe. According to a study conducted

in 2010, about 5,905 biogas plants were operating in Germany. Most of these plants
were power plants. By burning biogas in these plants, electric power is produced.
This electrical power is then fed into the power grid. The total electrical capacity of
these power plants was approximately 2,290 Mega Watts.[3]

1.11 Applications of biogas:

Biogas can be utilized for electricity production

If biogas is compressed, it can replace compressed natural gas, for use in vehicles.
Biogas can be used for cooking purpose, space heating and water heating.

[3] www.tutorvista.com

CHAPTER 2

ANAEROBIC DIGESTION
2.1 Anaerobic digestion:

17
It includes processes by which microorganisms break down biodegradable material anaerobic
ally (in the absence of oxygen). The fermentation process used industrially to make food and
drink products, as well as home fermentation, uses anaerobic digestion.

The digestion process consists of four phases:

Hydrolysis
Acidogenesis
Acetogenesis
Methanogenesis

2.1.1.1 Hydrolysis:

Biomass is composed of large organic polymers. These long chains must be broken down
into smaller parts so that the bacteria in anaerobic digesters can access the energy potential of
the material. These smaller constituent parts also called as monomers, are then readily
available to other bacteria. The process of decomposing or breaking of these large chains and
dissolving these smaller molecules into solution is known as hydrolysis.

Through this process the complex organic molecules are decomposed into simple sugars,
amino acids, and fatty acids. The long chain organic compounds (e.g. proteins, fats,
carbohydrates) are broken down into simple organic compounds (e.g. amino acids, fatty
acids, sugars) through bacterial action.

2.1.1.2 Acidogenesis:

The products produced as a result of hydrolysis are subsequently metabolized in this phase by
acidogenic bacteria and decomposed into short chain fatty acids (acetic acid, propionic acid,
butyric acid, valeric acid) and alcohol. Acetic acid, hydrogen and carbon dioxide act as initial
products for methane formation.

2.1.1.3 Acetogenesis:

In this phase, the organic acids and alcohols are broken down into acetic acid, hydrogen and
carbon dioxide by the action of acetogenic bacteria which are the major compounds in biogas
production.

18
In this process, simple molecules produced through the acidogenesis process are further
digested by acetogens that results in the formation of largely acetic acid, as well as carbon
dioxide and hydrogen.

2.1.1.4 Methanogenesis:

In methanogenesis, the products formed in the previous phases are converted into methane
and carbon dioxide and water by the action of methanogenic micro-organisms (archaea).
These components make up the majority of the biogas emitted from the system.

2.1.2 Chemical equations of the overall process:[4]

C6H12O6 + nH2O nC6H12O6 (Hydrolysis)

C6H12O6 C4H8O2 + 2CO2 +2H2 (acidogenesis)

C4H8O2 + 2H2O 2C2H4O2 +2H2 (acetogenesis)

CO2 + 4H2 CH4 + 2H2O (methanogenesis)

C2H4O2 CH4 + CO2 (methanogenesis)

A simplified chemical equation for the overall processes described above is as follows:

C6H12O6 3CO2 + 3CH4

[4] World Applied Sciences Journal 9 (5): 537-545, 2010ISSN 1818-4952 IDOSI Publications, 2010Corresponding Author: IlaboyaIdowu Rudolph, Department of Chemical Engineering,
PMB 0006, Igbinedion University Okada,Edo State, Nigeria

19
 Fig. 2.1 Plug Flow Digesters[4]

2.1.3 Process stages:

Fig. 2.2 Process stages [5]

[5] www.esru.strath.ac.uk

20
2.1.4 Flow Diagram of the processes:

Fig 2.3Flow Diagram of the processes[5]

2.1.5 Temperature:

The two conventional operational temperature levels for anaerobic digesters are determined
by the species of methanogens in the digesters.

Mesophilic digestion takes place optimally around 30 to 38 C, or at ambient

temperatures between 20 and 45 C, where mesophiles are the primary microorganism
present.
Thermophilic digestion takes place optimally around 49 to 57 C, or at elevated
temperatures up to 70 C, where thermophiles are the primary microorganisms
present.

21
2.2 POLYVINYL CHLORIDE
2.2.1 Chemical properties:
2.2.1.1 Introduction:
1. PVC accidently formed in 1872 when polymer appeared as a white solid inside a flask
of vinyl chloride which are exposed to sun light.
2. The method to use polyvinyl chloride on commercial level developed in 1926.
3. Polyvinyl chloride is used in construction of pipes, profile applications, bottles, non-
food packaging, water tanks.
4. To use more easily we can add plasticizer in it, the most widely used phthalates, in
this form it is used in plumbing, electric cable insulation, inflatable products and
many other applications where it replaces rubber.

2.2.1.2 How to Produce:

1. It is produce by polymerization of monomer vinyl chloride as in figure

2. Approximately 80% of the production involves suspension polymerization. The

suspension polymerization having an average particle size allows 100-180 microns,
and the average size of emulsion polymerization gives greater than about 0.2 microns
is much smaller.
3. VCM and water is introduced into the reactor and the polymerization initiator, and
other additives. The reaction vessel is tight to contain the VCM pressure. The contents
of the reaction vessel are mixed continuously kept in suspension and to ensure
uniform particle size PVC resin.
4. It is exothermic reaction, and therefore require cooling. It also reduces the volume in
the reaction process (PVC is more intense than VCM), continuously adding water to
the mixture to maintain the suspension.

5. Polymerization agent is mixed in a VCM drops caused by the compound known as

initiators. These compounds are broken, start a chain reaction of radical behavior.
Includes typical initiator and dioctyl peroxide dicarbonate, both of which have fragile
O-O bonds. Some entrepreneurs start fast response, but soon rot and other sponsors
have the opposite effect. And is often used as a combination of two different
initiators, to obtain a uniform rate of polymerization. After the polymer increased by
about 10-fold, VCM in the polymer deposition short decline, and the acceleration of
polymerization and the solvent-swollen particles continue. Commercial weight of the
polymer ranges from 100,000 to 200,000, and the average number molecular weight
ranging from 45,000 to 64,000 average molecular weight.

6. Once the reaction track and lift gas was stripped to remove excess slurry PVC VCM,
which is recovered. Polymers, then centrifuged to remove water. And before drying

22
 the slurry in a hot air bed, and the resulting powder was sieved storage or cute. In
general, the resulting polyvinyl chloride containing less than 1ppm VCM ratio. And
other production processes, such as micro-suspension polymerization and emulsion
polymerization, and the production of PVC having a small particle size (120-150
microns and 10 microns Evaluation PVC) have slightly different characteristics, and
different levels of the group and the application.

2.2.1.3 Microstructure:
Polymers are linear and powerful. Unilateral arrangement substantially straight tail,
which means that there is an alternating carbon center chloride. PVC is essentially a
three-dimensional chemical ataxia, which means that the relative stereochemistry of
the center randomized chloride. Between the sequence with a degree of regulation of
the given percentage of crystalline material is influential nature. About 57% of the
mass of PVC is chlorine. Related to the presence of vinyl chloride polymer
polyethylene groups provide a very different characteristics of the structure of the
material.

2.2.2 Physical properties:

PVC is a thermoplastic polymer. Rigid and flexible PVC generally classified on the

Property Rigid PVC Flexible PVC

Density [g/cm3] [6] 1.31.45 1.11.35
[7]
Thermal conductivity 0.14-0.28 0.14-0.17
[W/(mK)]
Yield strength [psi] [6] 4500-8700 1450-3600
Young's modulus[psi] 490,000
Flexural strength (yield) [psi] 10,500
Compression strength [psi] 9500
Coefficient of thermal 5105
expansion (linear)
[mm/(mm C)]
Vicat B [C] 65-100 Not recommended
16
Resistivity [ m] 10 10121015
Surface resistivity [] 10131014 10111012
basis

[3] [6]
Table 2..1 Physical properties of PVC

23
2.2.3 Mechanical properties:
PVC have high hardness and mechanical properties. Enhanced mechanical properties
with increasing molecular weight, but decrease with increasing temperature. Solid
PVC (plastic) are very good mechanical properties, the elastic modulus of up
1500~3,000 MPa. Soft polyvinyl chloride (PVC flexible) elasticity 1.5~15 MPa.
However, the elongation at break of up to 200-450%. PVC friction is normal; static
friction coefficient of 0.4-0.5, and the dynamic friction coefficient is 0.23. [8]

2.2.4 Thermal and fire properties:

Crude PVC thermal stability is very bad, so a necessary process in order to add
thermal stability factor, to ensure that the characteristics of the product. PVC begins
to decompose when the temperature reaches 140 C, a melt temperature range of
about 160 . From hard PVC plantlets extending longitudinally, and having a good
flame flame, limiting oxygen index (LOI) of the reduction is up to 45 or more. LOI is
the lowest oxygen concentration, expressed as a percentage of the polymer will
support combustion, and noted that the air contains 20% oxygen content.

2.2.5 Electrical properties:

PVC is a polymer having good insulating properties, electrical insulating properties
but because of the highly polar nature is inferior to the non-polar polymers such as
polyethylene and polypropylene.

Since the dielectric constant, dielectric loss tangent values, and the size of the resistor
is high, and the corona resistance is not very good, which is usually applied to the
low-frequency dielectric material medium or low pressure.

2.2.6 Applications: [5]

1. PVC leads to relatively low cost, for a wide range of biological and chemical
applications.
2. It is used for sewerage pipes, and other pipe applications where corrosion limits
use of metals.
3. By the addition of plasticizers, it can be flexible enough for use in wire and cable
insulation applications.
4. uPVC widely used in the construction industry, low maintenance, especially in
Ireland, the United Kingdom, the United States and Canada.

[3]
At 60% relative humidity and room temperature
[6]
Titow 1984, p. 1186
[7]
Titow 1984, p. 1191

24
Because it is cheaper than metal so it is used in making musical instruments, it is a common
alternative to the instruments.

Fig 2.4 The handles of the Victorinox Swiss Army knives are made of PVC.

2.2.7 Sustainability: [4]

Unlike many plastic PVC is in production, including oil not only, but also contains
salt, it is abound. PVC recycling broken down into small pieces, and removal of
impurities, refined products, make PVC pure white. And can be recycled by nearly
seven times, and has about 140 years lifespan.

[4]
http://www.wasterecyclingnews.com/article/20120801/NEWS02/120809998/pvc-at-olympics-destined-for-reuse-or-
recycling
[5]
Ceresana, Market Study Polyvinyl Chloride, 2nd. edition, http://www.ceresana.com/en/market-
studies/plastics/polyvinyl-chloride/
[8]
Properties of PVC(polyvinyl chloride). JT-EXTRUDERMACHINE.COM

25
2.3 Digester:

The bio digester is a physical structure, commonly known as the biogas plant. As various
chemical and microbiological reactions take place within it, it is also called as bio-reactor or
anaerobic reactor. The major function of digester is to provide anaerobic environment within
it. As a chamber, it should be sealed i.e it should be air and water tight. Digesters can be
made using various materials and are available in different shapes and sizes.

2.3.1 Size of biogas unit:

The size of a biogas unit depends upon:

The amount and type of organic waste to be used in the digester

The objective of treating the organic waste (the production of energy or
organic fertilizer)
Demand of natural gas and consumption pattern
On-site nature of the soil and the level of ground water

2.3.2 Types of Digester:

There are different types of digesters:

2.3.2.1 Fixed Dome Digesters:

They are also known as hydraulic digesters. They are the most common type for biogas
production. Fixed dome digesters are mostly built under the ground. The size of the digester
depends on various factors such as the location, number of households, and the amount of
substrate available every day.

2.3.2.1.1 Parts of fixed dome digesters:

Mixing tank with inlet pipe and sand trap

Digester
Compensation and removal tank
Gasholder
Gas pipe
Entry hatch with gastight seal
Accumulation of thick sludge

26
 Outlet pipe
Reference level

2.3.2.1.2Construction of fixed dome digesters:

The construction cost of a fixed dome plant is relatively low. The fixed dome has no moving
parts, creating a long life of the digester (20 years and more). These digesters are usually
constructed under the ground to protect it from physical damage and saving space.

Fig 2.5 Fixed Dome Digesters[6]

2.3.2.1.3Operation:

The waste from the mixing chamber enters in the digester, and as the gas is produced, the
pressure builds up in the dome pushing the material into the expansion chamber where it can
be removed. Stirring is done that allows the slurry to exit.
The purpose of stirring is to limit the formation of a scum layer on top of the slurry that
reduces the production of gas. The choice of material has the following parameters:

Technical suitability
Cost-effectiveness
Availability in the region and transport costs
Availability of local skills for working with the particular building material.

27
2.3.2.2 Floating drum digester:

2.3.2.2.1 Parts of floating drum digester:

Floating drum digester has the following main parts:

Mixing area
Digester
Gas-holder
Slurry store
Gas pipe
Fill pipe

Fig 2.6 Floating drum digester[6]

2.3.2.2.2 Construction:

It has a cylindrical body, gasometer, feed pit and outlet pit .The digester is built using burnt-
clay bricks and cement. The cylindrical dome is made of metal sheets and moves up and
down as it stores and releases the biogas. It consists of an underground digester and a
cylindrical or dome shaper with a moving floating gas-holder or drum located on top. The
drum can float directly in the slurry or located in a separate water jacket. This drum collects
the gas for storage and moves up, as the gas is produced, and moves down, as gas is used.

28
This provides a more regulated gas pressure. A guided frame is used to provide support for
the gas-holder, but the floating drum should not touch the outer walls, because it can then be
damaged or get stuck.

It produces biogas at a constant pressure with variable volume. From the position of the
drum, the amount of biogas gathering under the drum is easily detectable. The floating drum
needs to be coated with paint in a constant interval to avoid rust.

2.3.2.3 Plug Flow Digester:

Plug flow digesters have a constant volume, but produce biogas at a variable pressure. They
consist of a narrow and long tank with an average length to width ratio of 5:1. The inlet and
outlet of the digester are located at opposite ends, kept above ground, while the remaining
parts of the digester is buried in the ground in an inclined position. The disadvantage with the
fixed dome and floating drum models is that once they are installed they are difficult to
move.

In order to avoid temperature fluctuations and maintain the process temperature, a shed roof
is placed on top of the digester to cover it, which acts as an insulation both during day and
night.

Fig 2.7 Plug flow digester[7]

2.3.2.3.1 Main advantages:

These digesters do not have moving parts therefore reducing risks for failure. They are easy
to install, easy handling, and adaptation to extreme conditions at high altitudes with low
temperatures. The transportation costs for the material to build the digester in hilly areas are
high, resulting in high capital cost. On the other hand, plug flow digesters are easy to
transport, which reduces the cost of the digester. It is also difficult to dig a large volume
under the ground to build digesters at high altitudes

29
2.3.2.4 Batch digesters:

They are loaded at once, maintained and closed for a convenient period, and the organic
matter is fermented and then unloaded at a later time. It is quite a simple system with small
operational requirements. Installation can be made in an anaerobic tank or in a series of tanks,
depending on the biogas demand, availability and amount of raw materials to be utilized.

Fig 2.8 Batch digesters [7]

Batch flow is most suitable for dry organic matters (solid materials), e.g. solid vegetable
waste. This type of bio wastes is fed into the digester as a single batch. The digester is
opened, digestate

is removed and the new batch replaces the digestate. The tank is then resealed and ready for
operation.

2.3.2.5 Continuous digesters:

Continuous digesters usually require daily loading and residue management. The process is
referred to as continuous since to every daily load corresponds a similar volume load of
fermented material. The biomass inside the digester moves through by the difference in
hydraulic heat, between the substrate entering the digester and the digestate coming out when
unloading. Each load requires a retention time, usually between 14 to 40 days. Continuous
digesters can have their retention period reduced by the introduction of agitation and heating

30
2.4 Gasholder:

A huge cylindrical tank for storing fuel gas under pressure is called gasholder. Gasholder is a
large container where gas is stored at atmospheric pressure and at ambient temperature.

2.4.1 Selection of a gasholder:

There are several important factors to be considered in the selection of a gasholder for the
recovery and storage of gases. These are:

Seal compatibility with contained gases

Suitability for use with wet/saturated gases and condensates
Suitability for use with gases carrying particulates/dust
Seal operating temperature range
Maximum gas flow rates (which convert to maximum piston operating speed)
Pressure profile
Simplicity of operation
Capital and long-term cost
Low Maintenance
The ideal gasholder has to have the potential to accommodate larger volumes in the
future.
Minimized Installation Period
Sealing Efficiency

2.4.2 Types of Gasholder:

Multi-Lift Water Sealed holder

Single Lift Water Sealed Holder
The M.A.N. Waterless Oil Sealed Holder
The Klonne Grease Sealed Holder
The Wiggins Double Stage, Dry Seal, Column Type Holder (thin shell)
The Single Big Seal Wiggins Holder (thick shell)

31
2.4.2.1 The Klonne Grease Sealed Holder:

They operate with a piston that can move within a cylindrical shell, with the gas underneath it
by means of a sealing system made up of circular rubber compound segments lubricated with
grease. The whole sealing assembly is pressed against the shell by an internal counterweight
system. The piston moves as more or less gas is stored underneath it.

Fig. 2.9 TheKlonne Grease Sealed Holder[7]

2.4.2.2 Ultra store Membrane Gas holder:

It is structure of steel digester covers. These PVC-coated, fabric membrane digester covers
offer high gas storage capacity.

Fig.2.10 Ultra store Membrane Gas holder[7]

2.4.2.3 Cable guided gasholders:

They use a complicated arrangement of at least three separate cables. A single lift gasholder
which elastic vie a series of pulleys .The top of the gasholder tank to the top of the gasholder
vessel and back, which would keep the cables stretched and the floating vessel in position.

32
 Fig.2.11 Cable guided gasholders[7]

2.4.2.4 Floating Roof Holders:

The floating roof gasholder allowed for a very simplified system .This system only moving
part was the piston. The piston was able to rise and fall for example guide rollers. The outer
cylindrical shell was similar in appearance to other gasholders, these gasholders were taller
and thinner.

Fig. 2.12 Floating Roof Holders[7]

It was also clear that the outer shell remained the same size and the roof of the structure was
permanently fixed. Early systems still had a water seal and a small water reservoir in the
annulus at the base. These gasholders allowed the large water tanks required on previous
gasholders to be dispensed with.

33
2.4.2.5 Spiral guided gasholders:

They operated based on spiral guided rails affixed to the side of the gasholder vessels. The
spiral rails engage with rollers on the edge of the tank in such a manner that the bell moved
up and down in a screw like fashion.

Fig.2.13 Spiral guided gasholders[7]

The vessels could be all left-handed, all right-handed, or successive combinations of both.
The rails on the outer lift were always affixed to the exterior of the vessel, but those on
succeeding lifts could be either interior or exterior, although the latter were invariably used

34
 CHAPTER 3

DESIGN AND CALCULATION

3.1 Design and Calculation of biogas plant solar reflector:

3.1.1 Planning a biogas plant:

1. Before building a biogas plant, there are different circumstances which should be
considered.
2. Failure or unsatisfactory performance of biogas units occur mostly due to planning
mistakes.
3. The consequences of such mistakes may be immediately evident or may only become
apparent after several years. Careful planning is important to eliminate mistakes.
4. As a biogas unit is an expensive investment, it should not be considered as a temporary
set-up.
5. Therefore, determining complete criteria and initial steps for the stable biogas plant are
the important.
6. Moreover, agricultural biogas plants must begin with an estimation of the quantitative
and qualitative energy requirements for the interested party.
7. Then, the biogas-generating potential must be calculated on the basis of the given
biomass production and compared to the energy demand. Both the energy demand and
the gas generating potential, however, are variables that cannot be accurately determined
in the planning phase. Sizing the plant (digester, gasholder, etc.) is the next step in the
planning process.
8. In the case of a family-size biogas plant intended primarily as a source of energy,
implementation should only be recommended, if the plant can be expected to cover the
calculated energy demand.

3.1.2 Select a Design:

Throughout the world, a countless number of designs of biogas plants have been developed
under specific climatic conditions. Choosing a design is essentially part of the planning
process. It is, however, important to familiarize with basic design considerations before the

35
actual planning process begins. This refers to the planning of a single biogas unit as well as to
the planning of biogas-programs with a regional scope.

3.1.3 Physical conditions:

The performance of a biogas plant is depend on local conditions can affect the
performance of biogas plant, local conditions are climate, soil conditions, substrate for
digester and building material availability.
In areas with generally low temperatures, insulation and heating devices may be
important.
If bedrock occurs frequently, the design must avoid deep excavation work.
The amount and type of substrate to be digested have a bearing on size and design of
the digester and the inlet and outlet construction.
The choice of design will also be based on the building materials which are available
reliably and at reasonable cost.
3.1.4 Skills and labor:

High sophistication levels of biogas technology require high levels of skills, from the planner
as well as from the constructor and user. Training costs compete with actual construction
costs for project resources. Higher technical sophistication also requires more expensive
supervision and, possibly, higher maintenance costs. To which extent prefabricated designs
are suitable depends largely on the cost of labor and transport.

3.1.5 Design of Biogas Reactor:

A biogas system is a means of digesting animal manure anaerobically to produce methane gas
which is burned to provide heat or light. The system consists of one or more digester tanks, a
gas holder, an arrangement of gas pipes, and one or more fixtures to burn the gas.

A biogas system requires a constant and large supply of manure. A system serving one family
needs the daily manure production of either lo-15 pigs, two or three horses, or two cows.

3.1.6 Selecting a location:

The system should be located:

1. Near the source of manure to avoid excessive handling of manure,

2. Near the kitchen or other gas usage area to minimize the amount of gas piping,

36
 3. Install at a place where maximum sun heat are available for increasing the temperature
of digester.

3.2 Calculation for design:

The size of the system depends on:

1. The desired volume of daily gas production,

2. The daily gas consumption,
3. Substrate input quantity,
The minimum volume of the gas holder should be 2m3.

Approximate quantity of gas required for some domestic usage are given in following table.

Activity Volume of gas

Cooking for a family of 5 or 6 persons 2m3 per day

Heating water in a 3m3 per day

100-liter tank
Lighting one lamp 0.1-0.15m3 per hour

Operating a two horse power stationary 0.9m3 per hour

Engine
Table 3.1 Volume gas required according to activity [9]

3.2.1 Sizing a biogas plant:

The size of the biogas plant depends on the quantity, quality and kind of available biomass
and on the digesting temperature. The following points should be considered

3.2.2 Equations to be used:

Vd = Sd RT [ m3 = m3/day number of days ][10]

Where:

Vd=digester volume
RT=retension time

[9] Biogas Digest Volume I Biogas Basics Information and Advisory Service on Appropriate Technology by Stefan Habermeh

37
 Sd=daily substrate input quantity

Sd= biomass (B) + water (W) [10]

The mixing ratio for dung and water (B:W) is 2:1.

G = VS Gy [ m3/d = kg m3/(dkg) ] [10]

Where:

G=amount of biogas generated each day

Gy=specific gas yield

VS = volatile solids

Volume of gas holder = 1/2 (volume of digester)[9]

3.2.3 Dimensions of gas holder:

For lighting a lamp:

The volume of gasholder Vg, depends on the relative rates of gas generation and gas
consumption. The gasholder must be designed to

cover the peak consumption rate.

hold the gas produced during the longest zero-consumption period.

3.2.4 Dimensions of digester:

For 150 gallons of water tank
Diameter = 36in = 0.9144 m
Radius = 0.9144/2 = 0.4572 m
Volume of digester = r2h
= 3.14 (0.4572)21.4986
[10]Digest Volume II Biogas - Application and Product Development by Stefan Habermehl (ISAT)

=3.140.20931.4986

=0.9836 m3

38
Now
We make calculations for 75 gallon water tank
Volume of gas cylinder = r2h
= 3.14 (0.3937) 21.4478

=0.7041 m3

3.2.5 Substrate input quantity:

Vd = Sd RT [ m3 = m3/day number of days ]
0.9836 m3 = Sd 10 days
Sd = 0.09836 m3/day
Substrate input (Sd) = biomass (B) + water (W) [m3/d]
0.09836 = 0.06557 + 0.0327

Density of cow dung () = 550 Kg/m3 [11]

= m/V
550 = m / 0.06557
m = 36.065 Kg/day

3.2.6 Calculating the daily gas production G:

G = VS Gy(solids) [ m3/d = kg m3/(dkg) ]
For VS:
VS = 8.7% of biomas of cow dung which is taken from table [10]
[1 m3=1000 liters]

VS = 0.08736.065 kg/day
VS=3.1376 kg/day
Gy = 0.30287
G = 3.13760.30287 [ m3/d = kg m3/(dkg) ]
G=0.95 m3/d

39
 CHAPTER 4
ECONOMIC ANALYSIS

4.1 ECONOMIC ANALYSIS

The main criterion for economic evaluation for this proposed concept is the after tax rate of
return. The first stage of this process is estimation of capital cost and the second,
determination of input cost and determination of input cost and products values. A based case
is then used to determine the current viability of such a concept. This case forms the basis of
the sensitivity analysis that considers the effect of feedstock cost and product values changes
on the long term viability of the plant.
Cost based calculation
Here are the following things on which the cost of the power plant is based
Cost of power plant
PVC pipe Rs 9/ft
Valve Rs 190
Lotion Rs 150
Gas pipe Rs 11/ft
Pipe clamp Rs 5
Elfy Rs 20
T Rs 10
150 gallon water tank Rs 6000
75 Gallon water tank Rs 3000
0
45 elbow Rs 20
Mixer bottle Rs 200
Filter bottle Rs 150
Copper pipe Rs 30 /ft
AC valve Rs 300
Turbine mirror Rs 130
Rubber pipe Rs 8/ft
LED switch Rs 25
Wires Rs 6 /ft
Resisters Rs 6/dozen
Arduino Rs 1100
Welding Rs 1200
Nuts & bolts Rs 300
Connectors Rs 120
Hex saw Blade Rs 30
2 pipe Rs 20/ft
Bike tire tube Rs 200

Avg. house gas usage 2m 3/day cost = Rs. 2x66/2.831m 3

1 month gas usage cost = Rs. 46.62x30 = Rs. 1398.7/month
Our gas production = 0.5m3/day
1 month equivalence gas cost = 0.5x30x (66/2.831)
Saving per month =Rs. 349.67/month
Payback time = 25000/349.67x12 = 5.95 years
Annual Capital Cost = (capital cost/life) + maintenance = (25000/10) +500 = Rs. 3000/yr

40
Annual gas generation = 0.5m3/dayx365days/year = 182.5m3/year
Price of our gas generated per year = Rs. (66/2.831)x182.5 = Rs. 4254.68/year
Earning per year = Price of our gas generated per year -Annual Capital Cost
= Rs. 4254.68-3000 =Rs. 1254/year
Energy production from 1 mole = 810KJ, 0.5m3 of methane = 0.3401kg = 340.1 g.
0.3401 mole have energy = 21.1995 KJ of energy
3
Total energy from 0.5m = 810 x 21.1995 = 17.17MJ
Initial temperature = 200C
Specific heat of water = 4.183KJ/kg
In order to find 1liter of boil water = Mass x Temperature change x Specific heat
= 1000 x (100-20) x 4.186 = 334.88kJ
For 1000 or high temperature more energy needed which will provide by heat of
vaporization
Which is for water = 2261kJ/kg
Energy needed = 2261+ 334.88 = 2595.88kJ/kg is required for boil 1kg of water
We have energy = 17.1x106/2595.8 = 66liter water can be boiled by this power plant

41
 CHAPTER 5

FABRICATION
After the solid modeling of the whole assembly in Solid Works, the three dimensional
visualization of the model provided useful information to fabricate the project in a more
systematic way. It clearly distinguished the components which were important and the
different dimensions as well as the variables which were directly related to them.

5.1 COMPONENTS
The components with their brief details are listed below.

5.1.1 Biogas digester:

It is the main component of Biogas plant. It is used to hold the substrate input (dung + water).
Fermentation process takes place in digester and all four processes are performed in this
component of biogas plant. The volume of digester should enough to hold that amount of
substrate which produce sufficient amount of gas to fulfill their requirement of gas for a
family. Material of the digester should not react with substrate and biogas components. For
bioreactor we use water tank by cutting its top side so that gas holder can slide in it easily.

5.1 Biogas Digester Fig. 5.2 Topless water tank

42
Then we use sliders so that Gas holder can easily slide in it without friction.

Fig 5.3 Sliders Fig. 5.4 Silicon on nuts and bolts

Then to avoid leakage we use silicon on nuts and bolts which are fixed in digester by making
holes in digester. And now our final digester is

Fig. 5.5 Final Digester Design

43
5.1.2 Gas holder:
It is a storage tank of biogas which is produce in digester. Gas holder should have enough
volume to fulfill requirements of gas consumption in a daily life. Pressure gauge is installed
on a gas holder to observe gas pressure in gas holder.

Fig. 5.6a Gas Holder Fig. 5.6b Final Gas Holder

5.1.3 PVC piping:

PVC (Poly Vinyl Chloride) piping, valve, union and bend etc. are used to join digester and
gas holder. PVC pressure pipes are rated for resistance to internal pressure at 20C. At
temperatures above 20C the maximum allowable operating pressure must be reduced in
proportion to the material strength. Use of PVC pipes in the temperature range from 20C up
to the recommended maximum continuous operating temperature of 60C is well defined.

44
 Fig. 5.7 PVC

5.1.4 Gas Pipe:

It is a flexible pipe use for transfer gas to the place where we cannot use iron pipes r other
hard pipes. We use this pipe to transfer biogas collector to filter.

5.1.5 Filters:

We use filter to purify the gas so that heat content of gas increased. First we pass gas from
water so that hydrogen sulphide removed from gas but now we have water content in
methane we want to remove that water content so in next step we use charcoal filter which on
reaction with methane absorbs the water content then heating coefficient of flame increases.
We bend the pipes by filling them Sand then both ends are closed by Cork and then heat that
pipe.

Fig. 5.8a Filter Fig. 5.8b Filter

5.1.6 Boiler:

We design and fabricate water tube boiler. In water tube boiler we pass water inside the tube
and heat is produced by burning gases outside the tubes and water boils by the process of
conduction. To fabricate water tube boiler we use copper tubes and empty can of paint. For
that firstly we cut the lower side of can with cutter.

45
Fig. 5.9 Cutting base of can with cutter Fig. 5.10 Bottomless can

Fig. 5.11 Copper tube Fig. 5.12 Superheat copper tube

Fig. 5.13 Copper tubes in boiler

Then we make spiral of copper tubes. Then we connect it with super heater copper tube and
place it in can.

5.1.6.1: Burner:

The burner in boiler is made up with lighters and copper tubes. Copper tube has five holes on
it which consist of venture type burners.

Fig. 5.14a Burner of boiler Fig. 5.14b Burner of boiler

46
5.1.6.2 Flame:
Fire is how critical research chemical, fire science, materials science, fluid mechanics and
heat transfer engineering disciplines of mechanical influence fire behavior interaction. In
other words, the fire is an important study of how to start a fire, and the deployment and
development.

Fig. 5.15 Flame Dynamics

5.1.7 Steam Turbine:

A steam turbine is a device that extracts thermal energy from pressurized steam and uses it to
do mechanical work on a rotating output shaft. Because the turbine generates rotary motion, it
is particularly suitable for use to drive generator. We fabricate turbine of light weight
material which is aluminum of thickness 0.1 cm. For this purpose we firstly cut circle of
aluminum a shown in figure

Fig. 5.16 Aluminum Circle

47
Then we made blades on sides of it.

Fig. 5.17 Blades of Turbine

At the end final design of turbine is in following shape.

Fig. 5.18 Turbine with stand

5.1.8 Fly Wheel:

Fly wheel is used to reduce or stabilize the fluctuations of rotating body. It is composed of
iron machined according to our requirement. Fly wheel is placed or connected with turbine
axis of rotation. Fly wheel weighs more than turbine blades which help turbine to minimize
sudden fluctuations in rotation.

Fig. 5.19 Fly Wheel

48
5.1.9 Generator:

We use a DC motor acting as a generator of 9 volts which converts rotating energy of pulley
into electrical energy.

Fig.5.20 Generator Fig. 5.21 LED as a Street Light

5.1.10 Light Emitting Diodes:

The light emitting diodes we use are of 3.2 volts and 20mA each. For demonstration purpose
we made street lights from them in our project.

5.1.11 Power bank:

To avoid fluctuations and for continuous electric supply we use a power bank mainly
rechargeable battery which is continuously on charging using generator this will also helps to
supply continuous electricity when gas is not available or we have any maintenance issue
regarding power plant for short span of time.

Fig.5.22 Power Bank

49
5.2 Stand:

Stand is used to hold mixer, filter, and power generation setup. Stand is made up of iron.
Stand manufactured by welding. This technique is of permanent fastening.

Stand has three parts:

1. Mixer Stand
2. Filter Stand
3. Power Generation Setup Stand

5.2.1 Mixer Stand:

It supports mixer which is use to mix dung with water so that slurry should be inappropriate
ratio. Mixer frame is manufactured by welding technique and material is used for
manufacturing is iron.

Fig. 5.23 Mixer Stand Fig. 7.24 Filter Stand

5.2.2 Filter stand:

The purpose of filter stand is to give proper fixed position to charcoal and water filter
containers. The frame of stand is manufactured by welding.

5.2.3 Power Generation Setup Stand:

Main function of this stand is to demonstrate a power plant setup on a single platform. This
stand is also manufactured by welding technique using iron pipe. Wooden sheet is used to
form a table for whole setup. Using aluminum foil and led we made a physical pattern of
street lights to demonstrate the power generation.

50
Fig.5.25 Power generation setup stand Fig. 7.25.1 Turbine Frame

1.2.3.1 Turbine frame

The main body of turbine on which shaft is placed using to bearings for minimizing the
frictional looses. Whole setup is enclosed in a glass body due to following reasons:

For easy understanding and demonstration purpose

To protect turbine from environmental effects
To ensure safe path for steam
Safety measures.

5.2.3.2 Boiler Stand

Boiler stand holds the boiler up right on their required position.

Fig. 5.25.2 Boiler Stand

5.2.3.3 Reservoir stand

Water storage is the basic need for running a boiler, as steam is formed from water.

51
5.3 Arduino:

Arduino UNO is a device which has AT mega 328 micro-controller used in it for
programming and automation. We used it as a data acquisition unit of temperature at boiler
inlet, outlet and digester also for generator voltage and current generation. It is also capable
of plotting continuous graph on screen using Matlab.

Temperature & Voltage Data Acquisition code along with its elaboration:

// Basic 4 Rely board connection

// Each relay is turned on for 2 seconds and then off.
// You can here them click as there state changes from off to on and on to
// off.
// You will also see the corresponding Red LED on the 4 Relay board
// light up when the relay is on.
// define names for the 4 Digital pins On the Arduino 4,5,6,7
// These data pins link to 4 Relay board pins IN1, IN2, IN3, IN4
/*

LCD Arduino
VSS 1 GND
VDD 2 +5V
VO 3 10k 20k Potentiometer or Ground
RS 4 Pin 12 (8)
RW 5 GND
Enable 6 Pin 11 (9)
D0 7 Not needed for 4-Bit
D1 8 Not needed for 4-Bit
D2 9 Not needed for 4-Bit
D3 10 Not needed for 4-Bit
D4 11 Pin 5
D5 12 Pin 4
D6 13 Pin 3
D7 14 Pin 2
A 15 +4.2V (Backlight +)
K 16 GND (Backlight -)
http://www.arduino.cc/en/Tutorial/LiquidCrystal
*/
#include <LiquidCrystal.h>
// initialize the library with the numbers of the interface pins
LiquidCrystal lcd(8, 9, 4, 5, 6, 7);
int analogInput0 = A0;
int analogInput1 = A1;
//for plotting graph on Matlab
if ~isempty(instrfind)
fclose (instrfind);
delete (instrfind);
end

52
clc
display ('serial port closed')

%User Defined Properties

serialPort = 'COM3'; % define COM port #
baudeRate = 9600;
plotTitle = 'Serial Data Log'; % plot title
xLabel = 'Elapsed Time (s)'; % x-axis label
yLabel = 'Data'; % y-axis label
plotGrid = 'on'; % 'off' to turn off grid
min = -10; % set y-min
max = 50; % set y-max
scrollWidth = 10; % display period in plot, plot entire data log if <= 0
delay = 0.0001; % make sure sample faster than resolution

%Define Function Variables

time = 0;
data = 0;
data2 = 0;
data3 = 0;
count = 0;

%Set up Plot
figure();
plotGraph = subplot(2,2,1);
plotGraph1 = subplot(2,2,2);
plotGraph2 = subplot(2,2,3);
plotGraph3 = subplot(2,2,4);

%plotGraph = plot(time,data);

% figure();
% plotGraph1 = plot(time,data2);
% figure();
% plotGraph2 = plot(time,data3);
% title(plotTitle,'FontSize',25);
% xlabel(xLabel,'FontSize',15);
% ylabel(yLabel,'FontSize',15);
% axis([0 10 min max]);
% grid(plotGrid);
%Open Serial COM Port
s = serial(serialPort, 'BaudRate',baudeRate)
disp('Close Plot to End Session');
fopen(s);
tic
while ishandle(plotGraph) && ishandle(plotGraph1) && ishandle(plotGraph2) %Loop
when Plot is Active
dat = fscanf(s,'%f'); %Read Data from Serial as Float
if(~isempty(dat) && isfloat(dat)) %Make sure Data Type is Correct
count = count + 1;

53
 time(count) = toc; %Extract Elapsed Time
data(count) = dat; %Extract 1st Data Element
dat = fscanf(s,'%f');
data2(count) = dat;
dat = fscanf(s,'%f');
data3(count) = dat;
data(count)
data2(count)
data3(count)

%Set Axis according to Scroll Width

if(scrollWidth > 0)
%set(plotGraph,'XData',time(time > time(count)-scrollWidth),'YData',data(time >
time(count)-scrollWidth));
plot(plotGraph,time(time > time(count)-scrollWidth),data(time > time(count)-
scrollWidth));
plot(plotGraph1,time(time > time(count)-scrollWidth),data2(time > time(count)-
scrollWidth));
plot(plotGraph2,time(time > time(count)-scrollWidth),data3(time > time(count)-
scrollWidth));
plot(plotGraph3,time(time > time(count)-scrollWidth),data3(time > time(count)-
scrollWidth));

axis([time(count)-scrollWidth time(count) min max]);

else
set(plotGraph,'XData',time,'YData',data);
axis([0 time(count) min max]);
end
%Allow MATLAB to Update Plot
pause(delay);
end
end
close all
%Close Serial COM Port and Delete useless Variables
fclose(s);
clear count dat delay max min baudRate plotGraph plotGrid plotTitle s ...
scrollWidth serialPort xLabel yLabel;

disp('Session Terminated...');

Fig. 5.26 Fig. 5.27 Fig. 5.28 Fig. 5.29

Connecting Wires LCD Bread Board Arduino UNO

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 Fig. 5.30 LCD display Fig. 5.31 LM 35

Temperature sensor

Fig. 5.32 Data Acquisition Circuit Fig. 5.33 Burning code

Fig. 5.34 Pressure Gauge

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5.4 Biomass power plant:

Fig. 5.35 Fabricated model of biomass power plant

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CONCLUSION

To overcome the energy crises in the world by generation of energy (Bio Gas) using waste
materials like animal dung, fruits, vegetable wastes and other organic wastes. The gas
produced can be used as domestic as well as commercial purposes.

We used moveable type reactor. The efficiency of a Bio-gas reactor in winter season (normal
temperature) is less than 30% but as the temperature approaches to 50oC-60oC, efficiency
increases to 60%. Therefore our focus is to attain a temperature of 50oC and above using the
solar energy.

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BIBLIOGRAPHY

The Possibilities for Biogas in Bolivia: Symbioses Between Generators of Organic Residues,
Biogas Producers and Biogas Users by Master Thesis

Biogas Digest Volume I Biogas Basics Information and Advisory Service on Appropriate
Technology by Stefan Habermehl

Biogas Digest Volume II Biogas - Application and Product Development by Stefan

Habermehl

Designing a Biogas System Technical Note No.SAN.3.D.4

http://solarcooking.wikia.com/wiki/Parabolic_solar_reflectors

http://www.builditsolar.com/Experimental/SunSim/SunSim.htm

http://www.journeytoforever.org

http://www.anaerobic-digestion.com/index.php

http://www.biogas.psu.edu

http://www.arti-india.org/content/view/12/28

http://www.ruralcostarica.com/biogas.html

http://www.fao.org/docrep/t0541e/T0541E00.htm#Contents

http://www.aadl.co.uk/properties-of-aluminium.html

http://www.powerfromthesun.net/Book/chapter08/chapter08.html

http://www.fossilfreedom.com/increase-output.html

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REFERCENCES

[1] Studies on Biogas Generation from Agricultural Waste; Analysis of the Effects of
Alkaline on Gas Generation by I.R. Ilaboya, 2F.F. Asekhame, 3M.O. Ezugwu, 4A.A. Erameh
and 5F.E. Omofuma

[2]http://www.PermaCultureScience.org

[3] http://www.tutorvista.com

[4] World Applied Sciences Journal 9 (5): 537-545, 2010 ISSN 1818-4952 IDOSI Publications, 2010

Corresponding Author: IlaboyaIdowu Rudolph, Department of Chemical Engineering, PMB 0006,

Igbinedion University Okada, Edo State, Nigeria

[5] http://www.esru.strath.ac.uk

[6] http://www.energypedia.info/images/0/03/Nicarao_biogas.gif

[7] http://www.enst.umd.edu/sites/default/files/_images/uploaded/Digester%20overview.jpg

[8] http://www.polizeros.com/wp-content/uploads/2009/09/solar-reflectors.jpg

[9] Biogas Digest Volume I Biogas Basics Information and Advisory Service on Appropriate
Technology by Stefan Habermehl

[10]Digest Volume II Biogas - Application and Product Development by Stefan Habermehl

(ISAT)

[11] Physical characteristics of animal manure by F.Thirion, Chabot, D,Andeler

[12] Measurement and instrumentation by Alan S. Morris & Reza Langari

[13] http://www.thermopedia.com/content/1197/

[14] http://www.rivetsonline.com/

[15] http://www.journeytoforever.org

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[a] bourdon tube http://engitube.wordpress.com/2011/11/09/what-is-bourdon-tube-
pressure-gauge/

[b] Flat position welding http://pipingnfabrication.blogspot.com/2011_04_01_archive.html

[c] Solid rivets http://mumbai.khojle.in/ads/mushroom-head-solid-rivets-rivtool-

enterprises/12371434

[d] high strength rivets http://news.thomasnet.com/fullstory/High-Strength-Structural-

Rivets-resist-rattle-and-vibration-553944

[e] semi tubular rivets http://www.semitubularrivets.com/

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